Author Topic: DL650AL5 Clutch Cover (Read 1928 times)

matt-drummer · « **on:** April 02, 2020, 13:23:27 »

Hi,

I bought a DL650AL5 last year, used but in really nice condition. There are a couple of parts that I want to smarten up and although I could remove and repaint the parts I thought I would get a better outcome buy just buying new parts, they were not really cheap but they were not that expensive either.

One of the parts I want to replace is part of the clutch cover, it has a chip in the finish and it bugs me.

So the part arrived today but it doesn't look quite as I expected, I have ordered a workshop manual but someone here may know the answer.

It is part number 10 in this drawing

https://www.bike-parts-suz.com/Suzuki-motorcycle/650-MOTO/V-STROM/2015/DL650XA-L5-E99-/ENGINE-TRANSMISSION/CASING/11111000/11111006/M/6152

I expected it would bolt on from inside part number 1 (the main clutch side case) but there are no threads in the three lugs inside part number 10.

As far as I can see, it looks as though this part is a push fit, can that really be correct.

I can take some photos when I get home to help but maybe someone is familiar with this part and will be able to help me just from the drawing.

Thanks in advance,

Matthew.

roganjoshing · « **Reply #1 on:** April 02, 2020, 13:35:48 »

I get a 404 error when I click the link - not sure if that's me or you

matt-drummer · « **Reply #2 on:** April 02, 2020, 13:43:49 »

It was me, sort of, it is a Suzuki parts website that doesn't go back to the page address.

Maybe I have fixed it now.

There is a side view of the complete casing, it makes it look as if there are three bolt holes straight through the part number 10, but there are not. There are no bolts or holes on my new part, or the part on my bike and my bike looks like all the pictures I can find online.

What does the damper, part number 11 do? I don't see this part on older 650's and it would appear part 10 attaches to part 11.

tallpaul · « **Reply #3 on:** April 02, 2020, 14:17:50 »

I'm going to hazard a huge guess and say it's for noise suppression. That's to say it blocks the sound of all the rattles and mechanical noises from being heard by the rider. Not that noises are anything to worry about but not all the noise a bike makes comes from the air box or the exhaust.

matt-drummer · « **Reply #4 on:** April 02, 2020, 14:35:34 »

Maybe it's for noise, maybe for smoother clutch operation, or both? Wet clutches don't rattle like a dry clutch? I assume my bike is a wet clutch?

I'm not sure how it works though, it must be stationary, it can't spin with the clutch assembly?

It does seem that part 10 attaches to it.

I know a bit, more about cars than bikes (I built a couple of rally cars in my youth) but assuming it is a wet clutch, part 10 is never going to hold oil in, there is no gasket or o ring, it really does look like it is just a push fit, bit I don't really want to pull or lever the old one off when I have no idea what I am dealing with.

matt-drummer · « **Reply #5 on:** April 02, 2020, 14:42:48 »

It looks like the damper (11) sits outside the main clutch cover (1) and it attached by three bolts (12) from inside the main clutch cover (1) and part 10 then attaches to part 11 using three lugs.

With no threads or bolt holes it can only be a push fit?

matt-drummer · « **Reply #6 on:** April 02, 2020, 15:41:46 »

Here are photos of my bike and the new part.

UK_Vstrom650 · « **Reply #7 on:** April 02, 2020, 17:31:31 »

I guess if your current one just pulls off...

Rusty Nuts · « **Reply #8 on:** April 02, 2020, 17:39:47 »

Got a pic of the bike after you took that bit off? How did you get it off?

Rusty Nuts · « **Reply #9 on:** April 02, 2020, 17:47:16 »

Part 11 is indeed a damper, 10 is the outer cover. I see no bolts or screws listed, it looks like a push fit sandwich.

tallpaul · « **Reply #10 on:** April 02, 2020, 17:50:22 »

So possibly to dampen vibration?

matt-drummer · « **Reply #11 on:** April 02, 2020, 18:01:49 »

I have not taken it off yet!

That is the new part.

I think the cover just pulls off but I wanted to check if someone knew for sure before I attempted it.

mrp192 · « **Reply #12 on:** April 02, 2020, 18:08:16 »

Looked in my Haynes for you and they don’t remove it separately from the clutch cover. Some of the big dealers still have their workshops open, maybe a phone call will put your mind at rest about pulling it off.

matt-drummer · « **Reply #13 on:** April 02, 2020, 18:16:08 »

Thank you.

I could not find anything anywhere about this.

I guess it is not something that many people will do.

I think I will give it a gentle pull and see what it feels like, if it feels good I will pull harder!

Rusty Nuts · « **Reply #14 on:** April 02, 2020, 19:09:34 »

You're right, there's bugger all on 't web. All I have found are these pics, which show the inner cover with three holes where your three pegs are. They seem to be blind holes from looking at the inside picture.
I've been looking for pictures of the rubber damper to see what pegs / holes that has, but it looks as if that's a secret as well.

Dark-Strom · « **Reply #15 on:** April 02, 2020, 19:30:12 »

Hmm could be wrong …
there seems to be a slight flat to the top of the holes on the outside of the casing(holes look like they go right through), suggesting the lugs and holes meet rather than fit together, I.e. might be screwed/bolted from the inside (again flats on the inside of the casing), there may also be a number of seals to stop oil leaking out??

matt-drummer · « **Reply #16 on:** April 02, 2020, 19:35:50 »

Quote removed

Yes, not much on the internet, but I think this has got me further.

This is the clutch cover casing (1) I think, without the damper (11).

I think the damper is bolted to this from the inside with three screws (12).

The my cover (10) is fixed to the damper (11)

matt-drummer · « **Reply #17 on:** April 02, 2020, 19:40:34 »

Quote removed

I think I see it now, there is no oil past part number 1, part number 1 only has three holes in it to bolt the damper (11) to and those bolts have washers (13) on them to stop oil passing.

The damper (11) attaches to the clutch casing (1) from inside and part 10 is just a cover that is a friction fit on the damper (11).

matt-drummer · « **Reply #18 on:** April 02, 2020, 19:42:25 »

Quote from: Rusty Nuts on April 02, 2020, 17:47:16

Part 11 is indeed a damper, 10 is the outer cover. I see no bolts or screws listed, it looks like a push fit sandwich.

And the side view I referred to earlier with three holes in is part 1 without the damper (11) and cover (10) attached.

Rusty Nuts · « **Reply #19 on:** April 02, 2020, 19:48:10 »

I hadn't spotted the bolt and gasket, there are three listed, you're on to something.